Respirator with stretch-panels

ABSTRACT

A disposable respirator made from a filter body having at least one stretch-panel incorporated therein. The stretch-panel allows the respirator to better conform to the wearer&#39;s face during movement due to talking, coughing, or general head or neck movement. There may be one or more stretch-panels located underneath the chin or over the cheeks of the wearer.

BACKGROUND OF THE INVENTION

The invention relates to filter masks which isolate both the mouth andnostrils of a wearer from the surrounding environment. Moreparticularly, the invention relates to a conforming, collapsible filtermask which requires only a headband to secure the filter mask to thewearer's head.

There are many situations today where it is necessary to filter the airwhich is inhaled and exhaled. Such filtration is primarily concernedwith removal of small particulate matter, such as dirt or bacteria, asopposed to gases or liquids, from the air. Perhaps the most commoninstance in which a filter mask is used is in the medical arts. However,the same filter masks which have application in the medical arts arealso, in many cases, well suited for use in industrial and domesticapplications.

In the medical arts, filter masks are often used to prevent substancesexhaled by the wearer from entering the surrounding environment. Thesame mask may also be used to protect the wearer from inhaling harmfulmicroorganisms. One of the more common applications of filter masks inthe medical arts is the wearing of masks by a surgical team whileperforming surgical procedures. A mask worn during surgical procedures,for example, desirably provides proper air filtration while still beingcomfortable for the wearer who may be wearing the same mask for severalhours.

In the industrial arts it is often necessary for individuals working in“clean room” environments to avoid the introduction of any substanceswhich may be exhaled by the wearer, into the clean room environment. Asin the medical arts applications, industrial applications may requirethe workers to wear their filter masks for extended periods of time.Therefore, it is desirable that a mask be comfortable and durable.

Other industrial applications require the filtration of the air which isinhaled by the wearer. Often construction or agricultural workers willbe working in a “dirty” environment in which the air would be harmful tobreathe if it were not filtered. Many times filter masks are used insuch circumstances to protect the wearer from harm. Unfortunately, manyworkers will simply go without a protective mask if they deem it toouncomfortable.

Besides the medical and industrial applications there are domesticapplications for such masks in the home such as home improvementprojects, particularly those involving sanding or cutting, yard work,and many hobbies.

Regardless of the application, the full benefits of the filter mask willnot be realized if inhaled or exhaled air is allowed to leak around theedges of the mask when held against the wearer's face. However, it ischallenging to construct a mask that will fit the facial configurationof all wearers without constructing the mask specifically for eachindividual face. Compounding this challenge is the fact that a wearer'sface naturally moves and changes in shape while wearing a mask. This canhappen when the wearer talks, chews, yawns, stretches, or the like.

It is therefore very desirable to design a mask that is relatively quickand easy to place on the face, and that will remain in the properposition while the wearer continues his or her ordinary activities. Itis further desirable to design a mask that is compact. Generally, a flatstorage configuration provides for the most compact storage. Moreover,it is desirable that a mask be economical, since most users of filtermasks dispose of the mask after limited use.

SUMMARY OF THE INVENTION

The present invention includes a disposable respirator which defines anarea surrounded by a periphery, the disposable respirator extendingacross a wearer's nose bridge, across each of the wearer's cheeks, andunderneath the wearer's chin for covering the nose and mouth of thewearer. The disposable respirator includes a filter body comprising anon-elastic material defining a first area, and a first stretch-panelhaving an outer edge defining a portion of the mask periphery, the firststretch-panel defining a second area. The first stretch-panel is anelastic material. The area of the first stretch-panel is less than thearea of the filter body.

In another aspect of the present invention, the respirator is made witha filter body sized to fit over the mouth and nose of the wearer, thefilter body having a top edge arranged to extend across the nose andcheeks of the wearer, a bottom edge arranged to extend along a wearer'sjaw line, and a seam edge arranged to extend between the wearer's noseto the wearer's chin; and a triangular elastic panel attached to thebottom edge of the filter body, wherein the stretch-panel is arranged tofit underneath the wearer's chin.

In yet another aspect of the present invention, the respirator is madefrom a filter body sized to fit over the mouth and nose of the wearer,the filter body having a top edge arranged to extend across a nose andupper cheeks of the wearer; a bottom edge arranged to extend along lowercheeks and underneath a chin of the wearer, wherein the bottom edge hastwo spaced apart notched portions; and a seam edge arranged to extendbetween the wearer's nose to the wearer's chin; and a stretch-paneldisposed within each of the of notched portions and attached to thefilter body.

Other aspects and features will be in part apparent and in part pointedout hereinafter.

BRIEF DESCRIPTION OF THE DRAWINGS

A full and enabling disclosure of the present invention, including thebest mode thereof, directed to one of ordinary skill in the art, is setforth more particularly in the remainder of the specification, whichmakes reference to the appended figures in which:

FIG. 1 is a side elevation of one embodiment of the respirator of thepresent invention in a flat folded configuration.

FIG. 2 is an exploded plan view of the various parts used to constructthe respirator of FIG. 1, prior to assembly.

FIG. 3 is a rear elevation of the respirator shown in FIG. 1, in anunfolded configuration.

FIG. 4 is a front perspective view of the respirator in FIG. 1 shown onthe face of a wearer with his head in a rearward tilt position.

FIG. 5 is a front perspective view of the respirator of FIG. 1, shown onthe face of a wearer with his head in an upright position.

FIG. 6 is a front elevation of a second embodiment of the respirator ofthe present invention in a flat-fold configuration.

FIG. 7 is a side elevation of a second embodiment of the respirator ofthe present invention shown on the face of a wearer.

FIG. 8 is a side elevation of a third embodiment of the respirator ofthe present invention.

FIG. 9 is a side elevation of a fourth embodiment of the respirator ofthe present invention.

FIG. 10 is a side elevation of a fifth embodiment of the respirator ofthe present invention.

DETAILED DESCRIPTION OF THE PRESENT INVENTION

The following definitions are used in the description of the presentinvention.

“Attach” and its derivatives refer to the joining, adhering, connecting,bonding, sewing together, or the like, of two elements. Two elementswill be considered to be attached together when they are integral withone another or attached directly to one another or indirectly to oneanother, such as when each is directly attached to intermediateelements. “Attach” and its derivatives include permanent, releasable, orrefastenable attachment. In addition, the attachment can be completedeither during the manufacturing process or by the end user.

“Connect” and its derivatives refer to the joining, adhering, bonding,attaching, sewing together, or the like, of two elements. Two elementswill be considered to be connected together when they are connecteddirectly to one another or indirectly to one another, such as when eachis directly connected to intermediate elements. “Connect” and itsderivatives include permanent, releasable, or refastenable connection.In addition, the connecting can be completed either during themanufacturing process or by the end user.

The terms “disposed on,” “disposed along,” “disposed with,” or “disposedtoward” and variations thereof are intended to mean that one element canbe integral with another element, or that one element can be a separatestructure bonded to or placed with or placed near another element.

“Layer” when used in the singular can have the dual meaning of a singleelement or a plurality of elements.

“Spunbonded fibers” refers to small diameter fibers which are formed byextruding molten thermoplastic material as filaments from a plurality offine, usually circular capillaries of a spinneret with the diameter ofthe extruded filaments then being rapidly reduced to fibers as by, forexample, in U.S. Pat. No. 4,340,563 to Appel et al., and U.S. Pat. No.3,692,618 to Dorschner et al., U.S. Pat. No. 3,802,817 to Matsuki etal., U.S. Pat. Nos. 3,338,992 and 3,341,394 to Kinney, U.S. Pat. No.3,502,763 to Hartman, and U.S. Pat. No. 3,542,615 to Dobo et al., thecontents of which are incorporated herein by reference in theirentirety. Spunbond fibers are generally continuous and have diametersgenerally greater than about 7 microns, more particularly, between about10 and about 20 microns.

“Stretch bonded laminate” refers to a composite material having at leasttwo layers in which one layer is a gatherable layer and the other layeris an elastic layer. The layers are joined together when the elasticlayer is extended from its original condition so that upon relaxing thelayers, the gatherable layer is gathered. Such a multilayer compositeelastic material may be stretched to the extent that the non-elasticmaterial gathered between the bond locations allows the elastic materialto elongate. One type of stretch bonded laminate is disclosed, forexample, by U.S. Pat. No. 4,720,415 to Vander Wielen et al., the contentof which is incorporated herein by reference in its entirety. Othercomposite elastic materials are disclosed in U.S. Pat. No. 4,789,699 toKieffer et al., U.S. Pat. No. 4,781,966 to Taylor and U.S. Pat. Nos.4,657,802 and 4,652,487 to Morman and U.S. Pat. No. 4,655,760 to Mormanet al., the contents of which are incorporated herein by reference intheir entirety.

“Necking” or “neck stretching” interchangeably refer to a method ofelongating a nonwoven fabric, generally in the machine direction, toreduce its width (cross-machine direction) in a controlled manner to adesired amount. The controlled stretching may take place under cool,room temperature or greater temperatures and is limited to an increasein overall dimension in the direction being stretched up to theelongation required to break the fabric, which in most cases is about1.2 to 1.6 times. When relaxed, the web retracts toward, but does notreturn to, its original dimensions. Such a process is disclosed, forexample, in U.S. Pat. No. 4,443,513 to Meitner and Notheis, U.S. Pat.Nos. 4,965,122, 4,981,747 and 5,114,781 to Morman and U.S. Pat. No.5,244,482 to Hassenboehier Jr. et al., the contents of which areincorporated herein by reference in their entirety.

“Ultrasonic bonding” refers to a process in which materials (fibers,webs, films, etc.) are joined by passing the materials between a sonichorn and anvil roll. An example of such a process is illustrated in U.S.Pat. No. 4,374,888 to Bornslaeger, the content of which is incorporatedherein by reference in its entirety.

“Thermal point bonding” involves passing materials (fibers, webs, films,etc.) to be bonded between a heated calender roll and an anvil roll. Thecalender roll is usually, though not always, patterned in some way sothat the entire fabric is not bonded across its entire surface, and theanvil roll is usually flat. As a result, various patterns for calenderrolls have been developed for functional as well as aesthetic reasons.Typically, the percent bonding area varies from around 10 percent toaround 30 percent of the area of the fabric laminate. As is well knownin the art, thermal point bonding holds the laminate layers together andimparts integrity to each individual layer by bonding filaments and/orfibers within each layer.

“Elastic” refers to any material, including a film, fiber, nonwoven web,or combination thereof, which upon application of a biasing force in atleast one direction, is stretchable to a stretched, biased length whichis at least about 110 percent, suitably at least about 130 percent, andparticularly at least about 150 percent, its relaxed, unstretchedlength, and which will recover at least 15 percent of its elongationupon release of the stretching, biasing force. In the presentapplication, a material need only possess these properties in at leastone direction to be defined as elastic.

“Recover” or “recovery” refers to a contraction of a stretched materialupon termination of a biasing force following stretching of the materialby application of the biasing force. For example, if a material having arelaxed, unbiased length of one (1) inch is elongated 50 percent bystretching to a length of one and one half (1.5) inches the materialwould have a stretched length that is 150 percent of its relaxed length.If this exemplary stretched material contracted, that is recovered to alength of one and one tenth (1.1) inches after release of the biasingand stretching force, the material would have recovered 80 percent (0.4inch) of its elongation.

“Polymer” generally includes but is not limited to, homopolymers,copolymers, such as for example, block, graft, random and alternatingcopolymers, terpolymers, etc. and blends and modifications thereof.Furthermore, unless otherwise specifically limited, the term “polymer”shall include all possible geometrical configurations of the molecule.These configurations include, but are not limited to isotactic,syndiotactic and random symmetries.

These terms may be defined with additional language in the remainingportions of the specification.

Reference will now be made in detail to embodiments of the invention,one or more examples of which are illustrated in the drawings. Eachexample is provided by way of explanation of the invention, and notmeant as a limitation of the invention. For example, featuresillustrated or described as part of one embodiment can be used withanother embodiment to yield still a third embodiment. It is intendedthat the present invention include these and other modifications andvariations.

The present invention is a respirator 10 that is generally constructedfrom a filter body 12 and one or more stretch-panels 14, exemplified bypanels 14A and 14B in FIGS. 1-10. As shown, respirator 10 preferably hasthe general shape of a cup defining an opening 11 that is generallyagainst the wearer's face when worn (see, FIG. 3). The filter bodyportion of the mask 10 is preferably held away from the wearer'snostrils and mouth. Such “off-the-face” style masks provide a breathingchamber to permit cooler wear and easier breathing.

The respirator is intended to be disposable, that is, used for a limitedperiod of time and disposed of rather than washed or otherwiserejuvenated for reuse. The stretch-panel(s) 14 may be located at variouslocations of the respirator providing that it coincides with the maskperiphery 16. Thus, a stretch-panel 14 at the mask periphery 16 maydesirably stretch in a direction that is approximately tangent orparallel to the periphery 16 so that the periphery 16 can selectivelyincrease in size as needed. More detailed non-limiting examples of thepresent invention are described below.

A first exemplary embodiment of the respirator 10, shown in FIGS. 1-5,may be constructed from a unitary filter body 12 and a singlestretch-panel 14, specifically referred to as panel 14A. Desirably,filter body 12 is formed from one of more layers of material asdescribed below. The filter body may be cut into a blank that issymmetric about a fold line 18. A fold is formed at fold line 18 whenthe constructed mask 10 is in a flat configuration (see FIGS. 1 and 2).Instead of the unitary body blank shown in FIG. 2, it is contemplatedthat two or more separate parts may form the filter body 12.

Referring now to FIG. 2, the overall shape of filter body 12 is definedby a top edge 22 flanked by a pair of side edges 24, which togetherextend across the nose bridge and along the cheeks of the wearer; a pairof bottom edges 25 that when joined together, extend along the lower jawof a wearer (see FIG. 4); and a pair of seam edges 26 that convergetogether from the inner end of each bottom edge 25 to the lower end ofthe fold line 18. Each edge 22, 24, 25 and/or 26 may be curved as shown,or a may have an angular configuration. It is desirable to have the sometype of headband attachment structure located near each junction ofedges 22 and 24, referenced as points “A” and “B” in FIG. 2. Forinstance, side edge 24 may be shaped to define tab members 27, used toaccommodate a headband attachment structure as described below.

Respirator 10 has an outer surface area (viewable when the mask isworn), and an opposite inner surface area. The outer surface area of therespirator 10 is defined as the sum of the filter body 12 outer surfacearea and the stretch-panel 14A outer surface area, minus any marginsused to connect these components together. For embodiments having morethan one stretch-panel, the outer surface of stretch-panel 14 is the sumof the individual outer surface areas for each stretch-panel.

Independent of any particular embodiment of respirator 10, the type offilter materials and/or media used may depend on the intended end use ofthe respirator by a consumer. For instance, different uses will requiredifferent levels of filtration, which is beyond the scope of the presentinvention. Desirably, the combined layers of the filter body providestructural stiffness such that mask 10 does not collapse against thenose and mouth while being worn.

As noted, suitable materials for the filter body 12 may include one ormore layers of material. In one embodiment, there are two layers ofmaterial. Outer layer 60 may be formed from a material that is (a) gaspermeable such that it permits air to pass through filter body 12 inboth directions, and (b) liquid impermeable such that it prevents liquidfrom passing through layer 60 in at least one direction. Layer 60 ispreferably arranged to help prevent the passage of liquids from theexterior of mask 10 to the interior of mask 10.

In another embodiment, filter body 12 is a three layer structure thatincludes an outer mask layer 60, an inner mask layer 62, and a middlelayer (not shown). In one particular embodiment, filter body 12 mayinclude outer mask layer 60 that is constructed from a spun-bondedpolypropylene that may have a 30.5 gsm basis weight. Alternativematerials for outer mask layer 60 include, but are not limited to,thermally-formed polyester-bonded carded web, bi-component and/or powderbonded polyethylene or polypropylene nonwovens, wet-laid nonwovens,cellulosic tissue, or a spunbond polyester. The basis weight of thesematerials may range from about 15 to about 200 gsm.

Inner mask layer 62 may be constructed from the same materials as layer60, or a in the alternative, a composite made from bicomponentpolyethylene and polypropylene, or a composite made from bicomponentpolyethylene and polyester. Layer 62 may also be constructed from apolyester and/or polyethylene material or a cellulosic tissue. In oneparticular embodiment, layer 62 is a thermally formed blended fiberbonded carded web. Desirably, layer 62 may have a basis weight of about17 gsm.

Selection of the number and type of the middle layers of filter media,which may be disposed between outer mask layer 60 and inner mask layer62, can depend on the degree and type of filtration required by thewearer. Suitable mediums for the middle layer include, but are notlimited to, melt-blown polypropylene, extruded polycarbonate, melt-blownpolyester, or melt-blown urethane, bicomponent spunbond and/or anexpanded polytetrafluoroethylene (PTFE) membrane. In one particularembodiment, the middle layer may be a filtrating material such aselectret-treated meltblown polypropylene having a basis weight ofroughly 70 gsm, or alternatively, in the range of about 30 to about 120gsm. Further, the middle layer may be a combination of lighter weightlayers which together, add up to the desired basis weight. In onenon-limiting example, the middle layer may be a laminate formed from atwo plies of 50 gsm sheets.

Stretch-panel 14A may have various shapes. For example, as seen in FIG.2, stretch-panel 14A is basically a triangular wedge. It is contemplatedthat stretch-panel 14A may be asymmetric or symmetric as shown. Further,stretch-panel 14A may be a truncated ovoid, a rectangle, or even adecorative shape such as a lightning bolt. If there is more than onestretch-panel (as seen in latter embodiments of the present invention)they do not need to be identical shapes. Regardless of the exact shapeof any stretch-panel 14, it will characteristically have an edge, suchas edge 28, coincides with the periphery 16. Because the stretch-panelis designed to stretch, the shape desirably provides adequate areaadjacent the edge 28, and an adequate length for edge 28, so as not toprevent or limit stretching.

In the specific embodiment of FIG. 2, stretch-panel 14 is symmetric inshape and has a pair of sides 25′ which correspond in length to thebottom edges 25 on filter body 12. Desirably, the length of side 25 isabout equal to the length of side 25′. Most desirably, the triangularshape is truncated to create a short side 29. The purpose of truncationis to lessen the amount of material that comes together when seam 26 iscreated, specifically, at the outer end 30 of seam edges 26. Thisreduction of material will create a cleaner and more flexible seam.

Regardless of the stretch-panel location, stretch-panel 14 is desirablyconstructed from a material that is stretchable in at least onedirection, and air impermeable. The term “stretchable” describes amaterial that can stretch yet substantially recover to its initialpre-stretched dimension. The term “air impermeable” means that for allpractical purposes, the wearer cannot breathe through the stretch-panel14. One direction of stretch will substantially align with the peripheryedge 16. If periphery edge 16 is a straight edge, it is desirable thatthe stretch direction be about parallel with periphery 16. If periphery16 is a curved edge, it is desirable that the stretch direction be aboutparallel with a tangent of periphery 16 taken at about the midpoint of astretch-panel edge 28.

Suitable materials for the stretch-panel 14 include, but are not limitedto, films, nonwovens, or laminates that may include an elastic componentsuch as natural rubber latex, urethanes, elastic block copolymers (e.g.KRATON® from Kraton Polymers LLC or VISTAMAXX™ from ExxonMobil ChemicalCo.). Laminates may be in the form of necked materials such as neckedbonded nonwovens, or single- or dual-faced elastic film laminates suchas stretch bonded laminates. Desirably, these stretch-panel 14 materialscan be stretched to at least about 30% of an original length. However,it may be more desirable that such materials may be stretchable up toabout 100% of an original length, and most desirable that such materialsmay be stretchable up to about 200% of an original length. Thestretch-panel material may be air impermeable, or have a greaterfiltration performance (e.g. higher density, less porous, etc.)throughout the entire range of stretch than filter body 12.

Referring to FIG. 1, inside of top edge 22 of the mask 10, there may bean elongated malleable strip 52 as shown in FIGS. 1-3 and 5. Malleablestrip 52, known in the respirator art, is provided so that top edge 22of mask 10 can be configured to closely fit the contours of the nose ofthe wearer. In order to reduce “blow-by” associated with normalbreathing of the wearer, malleable strip 52 is preferably positioned atabout the center of top edge 22 and has a length in the range of about40 percent to about 70 percent of the total length of the top edge 22,defined as the distance between points A and B (see FIG. 2). Malleablemember 52 is preferably constructed from an aluminum-alloy strip with arectangular cross-section, but may also be a moldable or malleable metalor plastic member. Desirably, strip 52 is located between layers 60, 62,and may be held in position by adhesive, or by a border that is stitchedor heat sealed to closely surround strip 52 to prevent slippage.Malleable strip 52 may be used in any embodiment of the presentinvention.

The present invention may further include devices for attaching mask 10to the face of the wearer. Any type of conventional attachment devicesare within the scope and spirit of the invention. For example, the mask10 may include at least one strap for securing about the wearer's head.Alternatively, the mask may include straps extending from the top andbottom edges thereof for being tied around the wearer's head (notshown). In an alternative embodiment, the mask may include loops forbeing fitted over the ears of a wearer (not shown). A vast number ofattaching devices are well known to those skilled in the art and anymanner of such device may be incorporated in the present invention. Itshould be appreciated that a number of configurations and alternativeembodiments may be employed in the present invention, and that theinvention is not limited to any particular type of attachment method tothe face of the wearer. It is most desirable that the attaching deviceallows a wearer to place the respirator 10 onto the wearer in a mannerthat no gapping between the wearer's face and the periphery 16 occursaccidentally.

In one exemplary embodiment of the present invention, a simple headbandattachment device is a strap 42, and one of the ways to adjustablyconnect the headband strap 42 to a respirator 10 is through an aperturesuch as a slit 44. However, it is contemplated that additional clips,snaps, loops, hook and loop, buttons, or other mechanical fasteners maybe used to selectively and/or adjustably attach a headband straps 42 torespirator 10. For some applications, headband straps 42 are preferablyconstructed from resilient polyurethane, but may be constructed fromelastic rubber or a covered stretch yarn. The covered stretch yarn mayconsist of an elastomeric material wrapped with nylon or polyester. Forother applications, headband straps 42 may be double knitted headbandssuch as circle knitted polyester/LYCRA or nylon/LYCRA. Any flexiblestrip that is tolerated by the wearer may be used as a strap.

The assembly of mask 10 is as follows. Filter body 12 may be formed bycutting and connecting layers 60, 62 and optional middle layer (or otherlayers) to each other along margins adjacent the periphery 16. Suchconnections are preferably provided along top edge 22 and side edges 24,respectively. Referring to FIG. 1, the corresponding margins 65 may beformed by sewing, glue, heat sealing, welding, thermal point bonding,ultrasonic bonding and/or any other suitable connection procedure. Inaddition, a margin 67 may surround slit 33 for structural reinforcement.After the margins are formed on the filter body, the body-facing surfaceof the mask may be brought together by folding the blank about fold line18.

The stretch-panel edges 25′ are aligned with the filter body edges 25and bonded together to form outwardly facing fin seams 71. The edges 26may be further be bonded together in a like manner to create anoutwardly facing fin seam 73. The junction between seams 71 and 73 isbonded to prevent air leakage. Top edge 22, side edge 24, and exposededge 28 of the stretch-panel 14A cooperate with each other to define theperiphery 16 at the opening 11 of mask 10.

Desirably, each of the bonded seams 71, 73 share the characteristic ofbeing air impermeable. Thought it is contemplated that lap seams orother connection methods may be used. It is most desirable that seams 71and 73 be created via an air impermeable bond such as a pressure orultrasonic bond.

A second exemplary embodiment of the respirator 10, shown in FIG. 6, hasnot one, but two stretch-panels 14, designated as “14B.” Of course, morethan two stretch-panels may make up the overall surface area of mask 10.However, if stretch-panel 14 is air impermeable, it may not be desirableto incorporate too much stretch-panel material into the maskconfiguration as the mask 10 breathability could be compromised.

The shape of filter body 12 differs from that shown in FIG. 2 in that itis larger. The filter body 12 is symmetric about the fold line 18.Because there is no stretch-panel 14A located under the chin, the seamedges 26 extend all the way to edges 24. Seam edges 26 extend betweenpoints “C” and “E.” A fin seam 73 (or other seam type mentionedpreviously) formed by connecting the seam edges 26 together. Desirably,fin seam 73 is air impermeable as in the previous embodiment.

As described above, stretch-panels 14B may be triangular as shown, orthe other various shapes mentioned. Desirably, each stretch-panel islocated over the wearer's cheeks in a symmetric configuration. In theembodiment of FIG. 6, each stretch-panel 14B is located between theheadband structure, tab 27 at about point “D” and the end of seam 26 atpoint “C.” The stretch-panel 14B has an edge 28 that is shorter inlength than the distance 80 between points “C” and “D.” Desirably, thelength 82 of edge 28 is between about 0.2 to about 0.33 the length ofdistance 80. More desirably, length 82 is less than about 0.25 to about0.5 of the length of distance 80.

Referring now to FIG. 8, the side panels 14B may be positioned tocoincide with the tab member 27, and may have strap 42 or anotherheadband attachment device connected thereto.

Referring to FIGS. 9 and 10, the panels 14B as shown in FIGS. 6 and 8may be elongated and meet at the edge 26. It is further contemplated inthese embodiments; the stretch-panels 14B may be clear or translucent sothat one may be able to see the wearer's mouth.

Desirably, in the embodiments shown in FIGS. 6-10, like seams 71 of thefirst embodiment, seams 77 are outwardly facing fin seams created by anair impermeable bond such as a pressure or ultrasonic bond.

It is further contemplated that a direction of stretch may coincide withthe anticipated movement of the wearer. For instance, chewing may causethe wearer's jaw to move in direction 84 (see FIG. 6). Thus, the stretchdirection of panel 14B may substantially align with direction 84. So asnot to “lock up” the stretchability of panel 14B, the periphery may alsobe configured to align with the anticipated direction of movement.

The embodiment of respirator 10 as shown in FIG. 7 differs from theprevious embodiment in that an exhalation attachment device 100 replacesthe slit 44 and strap 42 (described in the embodiment of FIG. 1). Thisdevice 100 bypasses the filtration media of the respirator duringexhalation enabling faster expulsion of the hot humid exhaled breath.This improves the comfort of the respirator. Generally, vent 100 isdefined by a vent body having a fastening system attached thereto. Thefastening system comprises at least one pull-strap fastening component102 being formed integrally with a fastening component 104. Additionaldetails regarding the vent 100 are disclosed in U.S. patent applicationSer. No. 11/840,031, filed Aug. 16, 2007, and incorporated herein to theextent it is consistent with the present invention. Other applicableexhalation vents are shown and described in U.S. patent application Ser.No. 11/840,046, filed Aug. 16, 2007, and incorporated herein to theextent it is consistent with the present invention.

Although only a few exemplary embodiments of this invention have beendescribed in detail above, those skilled in the art will readilyappreciate that many modifications are possible in the exemplaryembodiments without materially departing from the novel teachings andadvantages of this invention. The mask may be configured as any numberof conventional masks. For example, the mask may be formed as atraditional molded cup or cone-shaped mask. Various configurations andshapes of masks are well known to those skilled in the art and any andall such conventional masks are within the scope and spirit of thepresent invention.

1. A disposable respirator which defines an area surrounded by aperiphery, the disposable respirator extending across a wearer's nosebridge, across each of the wearer's cheeks, and underneath the wearer'schin for covering the nose and mouth of the wearer, the disposablerespirator comprising: a filter body comprising a non-elastic materialdefining a body outer surface area; and a first stretch-panel comprisingan elastic material and having an outer edge defining a portion of themask periphery, the first stretch-panel defining a panel outer surfacearea, wherein the panel outer surface area is less than the filter outersurface area.
 2. The disposable respirator of claim 1 wherein the firststretch-panel comprises a stretch direction that is about parallel withthe outer edge of the first stretch-panel.
 3. The disposable respiratorof claim 1 wherein the first stretch-panel is substantially triangularin shape.
 4. The disposable respirator of claim 1 wherein the firststretch-panel is air impermeable.
 5. The disposable respirator of claim1 wherein the first stretch-panel is attached to the filter body with athermal bond.
 6. The disposable respirator of claim 1 further comprisinga head strap, wherein the head strap is connected to the filter body. 7.The disposable respirator of claim 1 further comprising a secondstretch-panel, wherein the first stretch-panel and the secondstretch-panel are attached to the filter body, and wherein the panelouter surface area is defined by the outer surface area of the firststretch-panel and the outer surface area of the second stretch-panel. 8.The disposable respirator of claim 7 wherein the first and the secondstretch-panels are substantially triangular in shape.
 9. The disposablerespirator of claim 7 wherein the first and the second stretch-panelscomprise four-sided polygons.
 10. The disposable respirator of claim 7wherein the first stretch-panel and the second stretch-panel are spacedapart and arranged to fit over each of the wearer's cheeks.
 11. Thedisposable respirator of claim 7 wherein the first stretch-panel and thesecond stretch-panel are connected together.
 12. The disposablerespirator of claim 1 further comprising an exhalation vent located onthe filter body or the first stretch-panel.
 13. The disposablerespirator of claim 1 wherein the filter body comprises a sheet-likeblank that is symmetric about a fold line.
 14. The disposable respiratorof claim 13 wherein the first stretch-panel comprises a fold line suchthat when the respirator is in a flat configuration, the stretch-panelis folded inward toward a body-facing surface of the respirator.
 15. Thedisposable respirator of claim 13 wherein the first stretch-panel issymmetrically disposed on the mask with respect to the fold line. 16.The disposable respirator of claim 15 wherein the connection between thefilter body and the first stretch-panel is air impermeable.
 17. Thedisposable respirator of claim 1 wherein the first stretch-panelcomprises an elastic film.
 18. The disposable respirator of claim 17wherein the first stretch-panel comprises a stretch bonded laminate. 19.A disposable respirator for a wearer, the respirator comprising: afilter body sized to fit over the mouth and nose of the wearer, thefilter body having a top edge arranged to extend across the nose andcheeks of the wearer, a bottom edge arranged to extend along a wearer'sjaw line, and a seam edge arranged to extend between the wearer's noseto the wearer's chin; and a triangular stretch-panel attached to thebottom edge of the filter body, wherein the stretch-panel is arranged tofit underneath the wearer's chin.
 20. A disposable respirator for awearer, the respirator comprising: a filter body sized to fit over themouth and nose of the wearer, the filter body having a top edge arrangedto extend across a nose and upper cheeks of the wearer, and a bottomedge arranged to extend along lower cheeks and underneath a chin of thewearer, wherein the bottom edge has two spaced apart notched portions;and a seam edge arranged to extend between the wearer's nose to thewearer's chin; and a stretch-panel disposed within each of the ofnotched portions and attached to the filter body.